High temperature electrolysis glow discharge device

ABSTRACT

The present invention provides a glow discharge assembly that includes an electrically conductive cylindrical screen, a flange assembly, an electrode, an insulator and a non-conductive granular material. The electrically conductive cylindrical screen has an open end and a closed end. The flange assembly is attached to and electrically connected to the open end of the electrically conductive cylindrical screen. The flange assembly has a hole with a first diameter aligned with a longitudinal axis of the electrically conductive cylindrical screen. The electrode is aligned with the longitudinal axis of the electrically conductive cylindrical screen and extends through the hole of the flange assembly into the electrically conductive cylindrical screen. The insulator seals the hole of the flange assembly around the electrode and maintains a substantially equidistant gap between the electrically conductive cylindrical screen and the electrode. The non-conductive granular material is disposed within the substantially equidistant gap.

PRIORITY CLAIM AND CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to and is: (1) a non-provisionalpatent application of U.S. Provisional Patent Application Ser. No.61/784,794 filed on Mar. 14, 2013; (2) a non-provisional patentapplication of U.S. Provisional Patent Application Ser. No. 61/803,992filed on Mar. 21, 2013; and (3) a continuation-in-part of U.S. patentapplication Ser. No. 13/586,449 filed on Aug. 15, 2012, which is acontinuation application of U.S. patent application Ser. No. 12/371,575filed on Feb. 13, 2009, now U.S. Pat. No. 8,278,810, which is: (a) acontinuation-in-part application of U.S. patent application Ser. No.12/288,170 filed on Oct. 16, 2008, which is a non-provisionalapplication of U.S. Provisional Patent Application Ser. No. 60/980,443filed on Oct. 16, 2007 and U.S. Provisional Patent Application Ser. No.61/028,386 filed on Feb. 13, 2008; (b) a continuation-in-partapplication of U.S. patent application Ser. No. 12/370,591 filed on Feb.12, 2009, now U.S. Pat. No. 8,074,439, which is non-provisional patentapplication of U.S. Provisional Patent Application Ser. No. 61/027,879filed on Feb. 12, 2008; and (c) a non-provisional patent application ofU.S. Provisional Patent Application Ser. No. 61/028,386 filed on Feb.13, 2008.

The entire contents of the foregoing applications are herebyincorporated herein by reference. This application is also related toU.S. Pat. No. 7,422,695 and U.S. Pat. No. 7,857,972 and multiple patentsand patent application that claim priority thereto.

FIELD OF THE INVENTION

The present invention relates generally to solid oxide electrolysiscells and plasma torches. More specifically, the present inventionrelates to a high temperature electrolysis glow discharge cell.

BACKGROUND OF THE INVENTION

Glow discharge and plasma systems are becoming every more present withthe emphasis on renewable fuels, pollution prevention, clean water andmore efficient processing methods. Glow discharge is also referred to aselectro-plasma, plasma electrolysis and high temperature electrolysis.In liquid glow discharge systems a plasma sheath is formed around thecathode located within an electrolysis cell.

U.S. Pat. No. 6,228,266 discloses a water treatment apparatus using aplasma reactor and a method of water treatment. The apparatus includes ahousing having a polluted water inlet and a polluted water outlet; aplurality of beads (e.g., nylon and other plastic type beads) filledinto the interior of the housing; a pair of electrodes, one of theelectrodes contacting with the bottom of the housing, another of theelectrodes contacting an upper portion of the uppermost beads; and apulse generator connected with the electrodes by a power cable forgenerating pulses. Some drawbacks of the '266 plasma reactor are therequirements of an extremely high voltage pulse generator (30 KW to 150KW), a plurality of various beads in a web shape and operating thereactor full from top to bottom. Likewise, the plasma reactor is notdesigned for separating a gas from the bulk liquid, nor can it recoverheat or generate hydrogen. In fact, the addition of air to the plasmareactor completely defeats the sole purpose of current research forgenerating hydrogen via electrolysis or plasma or a combination of both.If any hydrogen is generated within the plasma reactor, the addition ofair will cause the hydrogen to react with oxygen and form water. Also,there is no mention of any means for generating heat by cooling thecathode. Likewise, there is no mention of cooking organics unto thebeads, nor the ability to reboil and concentrate liquids (e.g., spentacids, black liquor, etc.), nor recovering caustic and sulfides fromblack liquor.

The following is a list of prior art similar to the '266 patent:

Patent No. Title 481,979 Apparatus for electrically purifying water501,732 Method of an apparatus for purifying water 3,798,784 Process andapparatus for the treatment of moist materials 4,265,747 Disinfectionand purification of fluids using focused laser radiation 4,624,765Separation of dispersed liquid phase from continuous fluid phase5,019,268 Method and apparatus for purifying waste water 5,048,404 Highpulsed voltage systems for extending the shelf life of pumpable foodproducts 5,326,530 High pulsed voltage systems for extending the shelflife of pumpable food products 5,348,629 Method and apparatus forelectrolytic processing of materials 5,368,724 Apparatus for treating aconfined liquid by means of a pulse electrical discharge 5,655,210Corona source for producing corona discharge and fluid waste treatmentwith corona discharge 5,746,984 Exhaust system with emissions storagedevice and plasma reactor 5,879,555 Electrochemical treatment ofmaterials 6,007,681 Apparatus and method for treating exhaust gas andpulse generator used therefor

Plasma arc torches are commonly used by fabricators, machine shops,welders and semi-conductor plants for cutting, gouging, welding, plasmaspraying coatings and manufacturing wafers. The plasma torch is operatedin one of two modes—transferred arc or non-transferred arc. The mostcommon torch found in many welding shops in the transferred arc plasmatorch. It is operated very similar to a DC welder in that a groundingclamp is attached to a workpiece. The operator, usually a welder,depresses a trigger on the plasma torch handle which forms a pilot arcbetween a centrally located cathode and an anode nozzle. When theoperator brings the plasma torch pilot arc close to the workpiece thearc is transferred from the anode nozzle via the electrically conductiveplasma to the workpiece. Hence the name transferred arc. Thenon-transferred arc plasma torch retains the arc within the torch. Quitesimply the arc remains attached to the anode nozzle. This requirescooling the anode. Common non-transferred arc plasma torches have a heatrejection rate of 30%. In other words, 30% of the total torch power isrejected as heat.

A major drawback in using plasma torches is the cost of inert gases suchas argon and hydrogen. There have been several attempts for forming theworking or plasma gas within the torch itself by using rejected heatfrom the electrodes to generate steam from water. The objective is toincrease the total efficiency of the torch as well as reduce plasma gascost. However, there is not a single working example that can runcontinuous duty. For example, the Multiplaz torch (U.S. Pat. Nos.6,087,616 and 6,156,994) is a small hand held torch that must bemanually refilled with water. The Multiplaz torch is not a continuoususe plasma torch.

Other prior art plasma torches are disclosed in the following patents.

Patent No. Title 3,567,898 Plasma cutting torch 3,830,428 Plasma torches4,311,897 Plasma arc torch and nozzle assembly 4,531,043 Method of andapparatus for stabilization of low-temperature plasma of an arc burner5,609,777 Electric-arc plasma steam torch 5,660,743 Plasma arc torchhaving water injection nozzle assembly

U.S. Pat. No. 4,791,268 discloses “an arc plasma torch includes amoveable cathode and a fixed anode which are automatically separated bythe buildup of gas pressure within the torch after a current flow isestablished between the cathode and the anode. The gas pressure draws anontransferred pilot arc to produce a plasma jet. The torch is thuscontact started, not through contact with an external workpiece, butthrough internal contact of the cathode and anode. Once the pilot arc isdrawn, the torch may be used in the nontransferred mode, or the arc maybe easily transferred to a workpiece. In a preferred embodiment, thecathode has a piston part which slidingly moves within a cylinder whensufficient gas pressure is supplied. In another embodiment, the torch isa hand-held unit and permits control of current and gas flow with asingle control.”

Typically, and as disclosed in the '268 patent, plasma torch gas flow isset upstream of the torch with a pressure regulator and flow regulator.In addition to transferred arc and non-transferred arc, plasma arctorches can be defined by arc starting method. The high voltage methodstarts by using a high voltage to jump the arc from the centered cathodeelectrode to the shield nozzle. The blow-back arc starting method issimilar to stick welding. For example, similar to a welder touching agrounded work-pieced then pulling back the electrode to form an arc, ablow-back torch uses the cutting gas to push the negative (−) cathodeelectrode away from the shield nozzle. Normally, in the blow-back torcha spring or compressed gas pushes the cathode towards the nozzle so thatit resets to the start mode when not in operation.

The '268 plasma torch is a blow-back type torch that uses the contactstarting method. Likewise, by depressing a button and/or trigger acurrent is allowed to flow through the torch and thus the torch is in adead-short mode. Immediately thereafter, gas flowing within a blow-backcontact starting torch pushes upon a piston to move the cathode awayfrom the anode thus forming an arc. Voltage is set based upon themaximum distance the cathode can be pushed back from the anode. Thereare no means for controlling voltage. Likewise, this type of torch canonly be operated in one mode—Plasma Arc. Backflowing material throughthe anode nozzle is not possible in the '268 plasma torch. Moreover,there is no disclosure of coupling this torch to a solid oxide glowdischarge cell.

U.S. Pat. No. 4,463,245 discloses “A plasma torch (40) comprises ahandle (41) having an upper end (41B) which houses the componentsforming a torch body (43). Body (33) incorporates a rod electrode (10)having an end which cooperates with an annular tip electrode (13) toform a spark gap. An ionizable fuel gas is fed to the spark gap via tube(44) within the handle (41), the gas from tube (44) flowing axiallyalong rod electrode (10) and being diverted radially through apertures(16) so as to impinge upon and act as a coolant for a thin-walledportion (14) of the annular tip electrode (13). With this arrangementthe heat generated by the electrical arc in the inter-electrode gap issubstantially confined to the annular tip portion (13A) of electrode(13) which is both consumable and replaceable in that portion (13A) issecured by screw threads to the adjoining portion (13B) of electrode(13) and which is integral with the thin-walled portion (14).” Onceagain there is no disclosure of coupling this torch to a solid oxideglow discharge cell.

The following is a list of prior art teachings with respect to startinga torch and modes of operation.

Patent No. Title 2,784,294 Welding torch 2,898,441 Arc torch pushstarting 2,923,809 Arc cutting of metals 3,004,189 Combinationautomatic-starting electrical plasma torch and gas shutoff valve3,082,314 Plasma arc torch 3,131,288 Electric arc torch 3,242,305 Plasmaretract arc torch 3,534,388 Arc torch cutting process 3,619,549 Arctorch cutting process 3,641,308 Plasma arc torch having liquid laminarflow jet for arc constriction 3,787,247 Water-scrubber cutting table3,833,787 Plasma jet cutting torch having reduced noise generatingcharacteristics 4,203,022 Method and apparatus for positioning a plasmaarc cutting torch 4,463,245 Plasma cutting and welding torches withimproved nozzle electrode cooling 4,567,346 Arc-striking method for awelding or cutting torch and a torch adapted to carry out said method

High temperature steam electrolysis and glow discharge are twotechnologies that are currently being viewed as the future for thehydrogen economy. Likewise, coal gasification is being viewed as thetechnology of choice for reducing carbon, sulfur dioxide and mercuryemissions from coal burning power plants. Renewables such as windturbines, hydroelectric and biomass are being exploited in order toreduce global warming.

Water is one of our most valuable resources. Copious amounts of waterare used in industrial processes with the end result of producingwastewater. Water treatment and wastewater treatment go hand in handwith the production of energy.

Therefore, a need exists for an all electric system that can regenerate,concentrate or convert waste materials such as black liquor, spentcaustic, phosphogypsum tailings water, wastewater biosolids and refinerytank bottoms to valuable feedstocks or products such as regeneratedcaustic soda, regeneratred sulfuric acid, concentrated phosphoric acid,syngas or hydrogen and steam. Although world-class size refineries,petrochem facilities, chemical plants, upstream heavy oil, oilsands, gasfacilities and pulp and paper mills would greatly benefit from such asystem, their exists a dire need for a distributed all electricmini-refinery that can treat water while also cogenerate heat and fuel.

SUMMARY OF THE INVENTION

The present invention provides an all electric system that canregenerate, concentrate or convert waste materials such as black liquor,spent caustic, phosphogypsum tailings water, wastewater biosolids andrefinery tank bottoms to valuable feedstocks or products such asregenerated caustic soda, regeneratred sulfuric acid, concentratedphosphoric acid, syngas or hydrogen and steam. Although world-class sizerefineries, petrochem facilities, chemical plants, upstream heavy oil,oilsands, gas facilities and pulp and paper mills would greatly benefitfrom such a system, their exists a dire need for a distributed allelectric mini-refinery that can treat water while also cogenerate heatand fuel.

The present invention provides a glow discharge electrode assembly thatincludes an electrically conductive cylindrical screen, a flangeassembly, an electrode, an insulator and a non-conductive granularmaterial. The electrically conductive cylindrical screen has an open endand a closed end. The flange assembly is attached to and electricallyconnected to the open end of the electrically conductive cylindricalscreen. The flange assembly has a hole with a first diameter alignedwith a longitudinal axis of the electrically conductive cylindricalscreen. The electrode is aligned with the longitudinal axis of theelectrically conductive cylindrical screen and extends through the holeof the flange assembly into the electrically conductive cylindricalscreen. The electrode has a second diameter that is smaller than thefirst diameter of the hole. The insulator seals the hole of the flangeassembly around the electrode and maintains a substantially equidistantgap between the electrically conductive cylindrical screen and theelectrode. The non-conductive granular material is disposed within thesubstantially equidistant gap, wherein (a) the non-conductive granularmaterial allows an electrically conductive fluid to flow between theelectrically conductive cylindrical screen and the electrode, and (b)the combination of the non-conductive granular material and theconductive fluid prevents electrical arcing between the electricallyconductive cylindrical screen and the electrode during an electric glowdischarge.

In addition, the present invention provides a glow discharge vessel thatincludes a vessel, a top cover and a glow discharge electrode assembly.The vessel has an open top, an outlet disposed in an upper portion ofthe vessel, and an inlet disposed in a lower portion of the vessel. Thetop cover seals the open top of the vessel, secures a glow dischargeelectrode assembly within the vessel, and provides a first electricalconnection and a second electrical connection to the glow dischargeelectrode assembly. The glow discharge electrode assembly includes anelectrically conductive cylindrical screen, a flange assembly, anelectrode, an insulator and a non-conductive granular material. Theelectrically conductive cylindrical screen has an open end and a closedend. The flange assembly is attached to and electrically connected tothe open end of the electrically conductive cylindrical screen. Theflange assembly has a hole with a first diameter aligned with alongitudinal axis of the electrically conductive cylindrical screen. Theelectrode is aligned with the longitudinal axis of the electricallyconductive cylindrical screen and extends through the hole of the flangeassembly into the electrically conductive cylindrical screen. Theelectrode has a second diameter that is smaller than the first diameterof the hole. The insulator seals the hole of the flange assembly aroundthe electrode and maintains a substantially equidistant gap between theelectrically conductive cylindrical screen and the electrode. Thenon-conductive granular material is disposed within the substantiallyequidistant gap, wherein (a) the non-conductive granular material allowsan electrically conductive fluid to flow between the electricallyconductive cylindrical screen and the electrode, and (b) the combinationof the non-conductive granular material and the conductive fluidprevents electrical arcing between the electrically conductivecylindrical screen and the electrode during an electric glow discharge.The electric glow discharge is created whenever (a) the first electricalconnection is connected to a DC electrical power supply such that theflange assembly and the electrically conductive cylindrical screen arean anode, (b) the second electrical connection is connected to the DCelectrical power supply such that the electrode is a cathode, and (c)the electrically conductive fluid is introduced into the gap via theinlet of the vessel. The cathode heats up during the electric glowdischarge.

The present invention also provides a glow discharge system thatincludes a vessel, one or more structural supports and two or more glowdischarge assemblies. The vessel has an outlet disposed in a top of thevessel, at least one inlet/outlet disposed in a side of the vessel, andan inlet disposed in a lower portion of the vessel. The one or morestructural supports are disposed within the vessel to secure the two ormore glow discharge assemblies within the vessel, and provide a firstelectrical connection and a second electrical connection to each glowdischarge electrode assembly. Each glow discharge electrode assemblyincludes an electrically conductive cylindrical screen, a flangeassembly, an electrode, an insulator and a non-conductive granularmaterial. The electrically conductive cylindrical screen has an open endand a closed end. The flange assembly is attached to and electricallyconnected to the open end of the electrically conductive cylindricalscreen. The flange assembly has a hole with a first diameter alignedwith a longitudinal axis of the electrically conductive cylindricalscreen. The electrode is aligned with the longitudinal axis of theelectrically conductive cylindrical screen and extends through the holeof the flange assembly into the electrically conductive cylindricalscreen. The electrode has a second diameter that is smaller than thefirst diameter of the hole. The insulator seals the hole of the flangeassembly around the electrode and maintains a substantially equidistantgap between the electrically conductive cylindrical screen and theelectrode. The non-conductive granular material is disposed within thesubstantially equidistant gap, wherein (a) the non-conductive granularmaterial allows an electrically conductive fluid to flow between theelectrically conductive cylindrical screen and the electrode, and (b)the combination of the non-conductive granular material and theconductive fluid prevents electrical arcing between the electricallyconductive cylindrical screen and the electrode during an electric glowdischarge. The electric glow discharge is created whenever (a) the firstelectrical connection is connected to a DC electrical power supply suchthat the flange assembly and the electrically conductive cylindricalscreen are an anode, (b) the second electrical connection is connectedto the DC electrical power supply such that the electrode is a cathode,and (c) the electrically conductive fluid is introduced into the gap viathe inlet of the vessel. The cathode heats up during the electric glowdischarge.

Moreover, the present invention provides a method for producing a steamthat includes the steps of providing a vessel, one or more structuralsupports and one or more glow discharge assemblies. The vessel has anoutlet disposed in a top of the vessel, at least one inlet/outletdisposed in a side of the vessel, and an inlet disposed in a lowerportion of the vessel. The one or more structural supports are disposedwithin the vessel to secure the two or more glow discharge assemblieswithin the vessel, and provide a first electrical connection and asecond electrical connection to each glow discharge electrode assembly.Each glow discharge electrode assembly includes an electricallyconductive cylindrical screen, a flange assembly, an electrode, aninsulator and a non-conductive granular material. The electricallyconductive cylindrical screen has an open end and a closed end. Theflange assembly is attached to and electrically connected to the openend of the electrically conductive cylindrical screen. The flangeassembly has a hole with a first diameter aligned with a longitudinalaxis of the electrically conductive cylindrical screen. The electrode isaligned with the longitudinal axis of the electrically conductivecylindrical screen and extends through the hole of the flange assemblyinto the electrically conductive cylindrical screen. The electrode has asecond diameter that is smaller than the first diameter of the hole. Theinsulator seals the hole of the flange assembly around the electrode andmaintains a substantially equidistant gap between the electricallyconductive cylindrical screen and the electrode. The non-conductivegranular material is disposed within the substantially equidistant gap,wherein (a) the non-conductive granular material allows an electricallyconductive fluid to flow between the electrically conductive cylindricalscreen and the electrode, and (b) the combination of the non-conductivegranular material and the conductive fluid prevents electrical arcingbetween the electrically conductive cylindrical screen and the electrodeduring an electric glow discharge. The electric glow discharge iscreated by: (1) connecting the first electrical connection to a DCelectrical power supply such that the flange assembly and theelectrically conductive cylindrical screen are an anode, (2) connectingthe second electrical connection to the DC electrical power supply suchthat the electrode is a cathode, and (3) introducing the electricallyconductive fluid into the gap via the inlet of the vessel. The steam isproduced using heat generated from the cathode during the electric glowdischarge.

The present invention is described in detail below with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be betterunderstood by referring to the following description in conjunction withthe accompanying drawings, in which:

FIG. 1 is a diagram of a plasma arc torch in accordance with oneembodiment of the present invention;

FIG. 2 is a cross-sectional view comparing and contrasting a solid oxidecell to a liquid electrolyte cell in accordance with one embodiment ofthe present invention;

FIG. 3 is a graph showing an operating curve a glow discharge cell inaccordance with one embodiment of the present invention.

FIG. 4 is a cross-sectional view of a glow discharge cell in accordancewith one embodiment of the present invention;

FIG. 5 is a cross-sectional view of a glow discharge cell in accordancewith another embodiment of the present invention;

FIG. 6 is a cross-sectional view of a Solid Oxide Plasma Arc TorchSystem in accordance with another embodiment of the present invention;

FIG. 7 is a cross-sectional view of a Solid Oxide Plasma Arc TorchSystem in accordance with another embodiment of the present invention;

FIG. 8 is a cross-sectional view of a Solid Oxide Transferred Arc PlasmaTorch in accordance with another embodiment of the present invention;

FIG. 9 is a cross-sectional view of a Solid Oxide Non-Transferred ArcPlasma Torch in accordance with another embodiment of the presentinvention;

FIG. 10 is a table showing the results of the tailings pond water andsolids analysis treated with one embodiment of the present invention;

FIG. 11 is a cross-sectional view of a glow discharge electrode assemblyparts in accordance with another embodiment of the present invention;

FIG. 12 is a cross-sectional view of a glow discharge electrode assemblyparts in accordance with another embodiment of the present invention;

FIG. 13 is a cross-sectional view of a glow discharge electrode assemblyin accordance with another embodiment of the present invention;

FIG. 14 is a cross-sectional view of a glow discharge electrode vesselin accordance with another embodiment of the present invention; and

FIG. 15 is a cross-sectional view of a glow discharge electrode systemwith multiple glow discharge electrode assemblies in accordance withanother embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention and do not delimit the scope of theinvention.

Now referring to FIG. 1, a plasma arc torch 100 in accordance with oneembodiment of the present invention is shown. The plasma arc torch 100is a modified version of the ARCWHIRL® device disclosed in U.S. Pat. No.7,422,695 (which is hereby incorporated by reference in its entirety)that produces unexpected results. More specifically, by attaching adischarge volute 102 to the bottom of the vessel 104, closing off thevortex finder, replacing the bottom electrode with a hollow electrodenozzle 106, an electrical arc can be maintained while discharging plasma108 through the hollow electrode nozzle 106 regardless of how much gas(e.g., air), fluid (e.g., water) or steam 110 is injected into plasmaarc torch 100. In addition, when a valve (not shown) is connected to thedischarge volute 102, the mass flow of plasma 108 discharged from thehollow electrode nozzle 106 can be controlled by throttling the valve(not shown) while adjusting the position of the first electrode 112using the linear actuator 114.

As a result, plasma arc torch 100 includes a cylindrical vessel 104having a first end 116 and a second end 118. A tangential inlet 120 isconnected to or proximate to the first end 116 and a tangential outlet136 (discharge volute) is connected to or proximate to the second end118. An electrode housing 122 is connected to the first end 116 of thecylindrical vessel 104 such that a first electrode 112 is aligned withthe longitudinal axis 124 of the cylindrical vessel 104, extends intothe cylindrical vessel 104, and can be moved along the longitudinal axis124. Moreover, a linear actuator 114 is connected to the first electrode112 to adjust the position of the first electrode 112 within thecylindrical vessel 104 along the longitudinal axis of the cylindricalvessel 124 as indicated by arrows 126. The hollow electrode nozzle 106is connected to the second end 118 of the cylindrical vessel 104 suchthat the center line of the hollow electrode nozzle 106 is aligned withthe longitudinal axis 124 of the cylindrical vessel 104. The shape ofthe hollow portion 128 of the hollow electrode nozzle 106 can becylindrical or conical. Moreover, the hollow electrode nozzle 106 canextend to the second end 118 of the cylindrical vessel 104 or extendinto the cylindrical vessel 104 as shown. As shown in FIG. 1, thetangential inlet 120 is volute attached to the first end 116 of thecylindrical vessel 104, the tangential outlet 136 is a volute attachedto the second end 118 of the cylindrical vessel 104, the electrodehousing 122 is connected to the inlet volute 120, and the hollowelectrode nozzle 106 (cylindrical configuration) is connected to thedischarge volute 102. Note that the plasma arc torch 100 is not shown toscale.

A power supply 130 is electrically connected to the plasma arc torch 100such that the first electrode 112 serves as the cathode and the hollowelectrode nozzle 106 serves as the anode. The voltage, power and type ofthe power supply 130 is dependant upon the size, configuration andfunction of the plasma arc torch 100. A gas (e.g., air), fluid (e.g.,water) or steam 110 is introduced into the tangential inlet 120 to forma vortex 132 within the cylindrical vessel 104 and exit through thetangential outlet 136 as discharge 134. The vortex 132 confines theplasma 108 within in the vessel 104 by the inertia (inertial confinementas opposed to magnetic confinement) caused by the angular momentum ofthe vortex, whirling, cyclonic or swirling flow of the gas (e.g., air),fluid (e.g., water) or steam 110 around the interior of the cylindricalvessel 104. During startup, the linear actuator 114 moves the firstelectrode 112 into contact with the hollow electrode nozzle 106 and thendraws the first electrode 112 back to create an electrical arc whichforms the plasma 108 that is discharged through the hollow electrodenozzle 106. During operation, the linear actuator 114 can adjust theposition of the first electrode 112 to change the plasma 108 dischargeor account for extended use of the first electrode 112.

Referring now to FIG. 2, a cross-sectional view comparing andcontrasting a solid oxide cell 200 to a liquid electrolyte cell 250 inaccordance with one embodiment of the present invention is shown. Anexperiment was conducted using the Liquid Electrolyte Cell 250. A carboncathode 202 was connected a linear actuator 204 in order to raise andlower the cathode 202 into a carbon anode crucible 206. An ESAB ESP 150DC power supply rated at 150 amps and an open circuit voltage (“OCV”) of370 VDC was used for the test. The power supply was “tricked out” inorder to operate at OCV.

In order to determine the sheath glow discharge length on the cathode202 as well as measure amps and volts the power supply was turned on andthen the linear actuator 204 was used to lower the cathode 202 into anelectrolyte solution of water and baking soda. Although a steady glowdischarge could be obtained the voltage and amps were too erratic torecord. Likewise, the power supply constantly surged and pulsed due toerratic current flow. As soon as the cathode 202 was lowered too deep,the glow discharge ceased and the cell went into an electrolysis mode.In addition, since boiling would occur quite rapidly and the electrolytewould foam up and go over the sides of the carbon crucible 206, foundrysand was added reduce the foam in the crucible 206.

The 8″ diameter anode crucible 206 was filled with sand and theelectrolyte was added to the crucible. Power was turned on and thecathode 202 was lowered into the sand and electrolyte. Unexpectedly, aglow discharge was formed immediately, but this time it appeared tospread out laterally from the cathode 202. A large amount of steam wasproduced such that it could not be seen how far the glow discharge hadextended through the sand.

Next, the sand was replaced with commonly available clear floralmarbles. When the cathode 202 was lowered into the marbles and bakingsoda/water solution, the electrolyte began to slowly boil. As soon asthe electrolyte began to boil a glow discharge spider web could be seenthroughout the marbles as shown the Solid Oxide Cell 200. Although thiswas completely unexpected at a much lower voltage than what has beendisclosed and published, what was completely unexpected is that the DCpower supply did not surge, pulse or operate erratically in any way. Agraph showing an operating curve for a glow discharge cell in accordancewith the present invention is shown in FIG. 3 based on various tests.The data is completely different from what is currently published withrespect to glow discharge graphs and curves developed from currentlyknown electro-plasma, plasma electrolysis or glow discharge reactors.Glow discharge cells can evaporate or concentrate liquids whilegenerating steam.

Now referring to FIG. 4, a cross-sectional view of a glow discharge cell400 in accordance with one embodiment of the present invention is shown.The glow discharge cell 400 includes an electrically conductivecylindrical vessel 402 having a first end 404 and a second end 406, andat least one inlet 408 and one outlet 410. A hollow electrode 412 isaligned with a longitudinal axis of the cylindrical vessel 402 andextends at least from the first end 404 to the second end 406 of thecylindrical vessel 402. The hollow electrode 412 also has an inlet 414and an outlet 416. A first insulator 418 seals the first end 404 of thecylindrical vessel 402 around the hollow electrode 412 and maintains asubstantially equidistant gap 420 between the cylindrical vessel 402 andthe hollow electrode 412. A second insulator 422 seals the second end406 of the cylindrical vessel 402 around the hollow electrode 412 andmaintains the substantially equidistant gap 420 between the cylindricalvessel 402 and the hollow electrode 412. A non-conductive granularmaterial 424 is disposed within the gap 420, wherein the non-conductivegranular material 424 (a) allows an electrically conductive fluid toflow between the cylindrical vessel 402 and the hollow electrode 412,and (b) prevents electrical arcing between the cylindrical vessel 402and the hollow electrode 412 during a electric glow discharge. Theelectric glow discharge is created whenever: (a) the glow discharge cell400 is connected to an electrical power source such that the cylindricalvessel 402 is an anode and the hollow electrode 412 is a cathode, and(b) the electrically conductive fluid is introduced into the gap 420.

The vessel 402 can be made of stainless steel and the hollow electrodecan be made of carbon. The non-conductive granular material 424 can bemarbles, ceramic beads, molecular sieve media, sand, limestone,activated carbon, zeolite, zirconium, alumina, rock salt, nut shell orwood chips. The electrical power supply can operate in a range from 50to 500 volts DC, or a range of 200 to 400 volts DC. The cathode 412 canreach a temperature of at least 500° C., at least 1000° C., or at least2000° C. during the electric glow discharge. The electrically conductivefluid comprises water, produced water, wastewater, tailings pond water,or other suitable fluid. The electrically conductive fluid can becreated by adding an electrolyte, such as baking soda, Nahcolite, lime,sodium chloride, ammonium sulfate, sodium sulfate or carbonic acid, to afluid.

Referring now to FIG. 5, a cross-sectional view of a glow discharge cell500 in accordance with another embodiment of the present invention isshown. The glow discharge cell 500 includes an electrically conductivecylindrical vessel 402 having a first end 404 and a closed second end502, an inlet proximate 408 to the first end 404, and an outlet 410centered in the closed second end 502. A hollow electrode 504 is alignedwith a longitudinal axis of the cylindrical vessel and extends at leastfrom the first end 404 into the cylindrical vessel 402. The hollowelectrode 504 has an inlet 414 and an outlet 416. A first insulator 418seals the first end 404 of the cylindrical vessel 402 around the hollowelectrode 504 and maintains a substantially equidistant gap 420 betweenthe cylindrical vessel 402 and the hollow electrode 504. Anon-conductive granular material 424 is disposed within the gap 420,wherein the non-conductive granular material 424 (a) allows anelectrically conductive fluid to flow between the cylindrical vessel 402and the hollow electrode 504, and (b) prevents electrical arcing betweenthe cylindrical vessel 402 and the hollow electrode 504 during aelectric glow discharge. The electric glow discharge is createdwhenever: (a) the glow discharge cell 500 is connected to an electricalpower source such that the cylindrical vessel 402 is an anode and thehollow electrode 504 is a cathode, and (b) the electrically conductivefluid is introduced into the gap 420.

The following examples will demonstrate the capabilities, usefulness andcompletely unobvious and unexpected results.

Example 1 Black Liquor

Now referring to FIG. 6, a cross-sectional view of a Solid Oxide PlasmaArc Torch System 600 in accordance with another embodiment of thepresent invention is shown. A plasma arc torch 100 is connected to thecell 500 via an eductor 602. Once again the cell 500 was filled with abaking soda and water solution. A pump was connected to the first volute31 of the plasma arc torch 100 via a 3-way valve 604 and the eductor602. The eductor 602 pulled a vacuum on the cell 500. The plasma exitingfrom the plasma arc torch 100 dramatically increased in size. Hence, anon-condensable gas B was produced within the cell 500. The color of thearc within the plasma arc torch 100 when viewed through the sightglass33 changed colors due to the gases produced from the HiTemper™ cell 500.Next, the 3-way valve 604 was adjusted to allow air and water F to flowinto the first volute 31 of plasma arc torch 100. The additional massflow increased the plasma G exiting from the plasma arc torch 100.Several pieces of stainless steel round bar were placed at the tip ofthe plasma G and melted to demonstrate the systems capabilities.Likewise, wood was carbonized by placing it within the plasma stream G.Thereafter the plasma G exiting from the plasma torch 100 was directedinto cyclone separator 610. The water and gases I exiting from theplasma arc torch 100 via second volute 34 flowed into a hydrocyclone 608via a valve 606. This allowed for rapid mixing and scrubbing of gaseswith the water in order to reduce the discharge of any hazardouscontaminants.

A sample of black liquor with 16% solids obtained from a pulp and papermill was charged to the glow discharge cell 500 in a sufficient volumeto cover the floral marbles 424. In contrast to other glow discharge orelectro plasma systems the solid oxide glow discharge cell does notrequire preheating of the electrolyte. The ESAB ESP 150 power supply wasturned on and the volts and amps were recorded by hand. Referringbriefly to FIG. 3, as soon as the power was turned on to the cell 500,the amp meter pegged out at 150. Hence, the name of the ESAB powersupply—ESP 150. It is rated at 150 amps. The voltage was steady between90 and 100 VDC. As soon as boiling occurred the voltage steadily climbedto OCV (370 VDC) while the amps dropped to 75.

The glow discharge cell 500 was operated until the amps fell almost tozero. Even at very low amps of less than 10 the voltage appeared to belocked on at 370 VDC. The cell 500 was allowed to cool and then openedto examine the marbles 424. It was surprising that there was no visibleliquid left in the cell 500 but all of the marbles 424 were coated orcoked with a black residue. The marbles 424 with the black residue wereshipped off for analysis. The residue was in the bottom of the containerand had come off of the marbles 424 during shipping. The analysis islisted in the table below, which demonstrates a novel method forconcentrating black liquor and coking organics. With a starting solidsconcentration of 16%, the solids were concentrated to 94.26% with onlyone evaporation step. Note that the sulfur (“S”) stayed in the residueand did not exit the cell 500.

-   -   Total Solids % 94.26    -   Ash %/ODS 83.64    -   ICP metal scan: results are reported on ODS basis

TABLE Black Liquor Results Metal Scan Unit F80015 Aluminum, Al mg/kg3590*  Arsenic, As mg/kg <50   Barium, Ba mg/kg 2240*  Boron, B mg/kg 60Cadmium, Cd mg/kg  2 Calcium, Ca mg/kg 29100*  Chromium, Cr mg/kg 31Cobalt, Co mg/kg <5 Copper, Cu mg/kg 19 Iron, Fe mg/kg 686* Lead, Pbmg/kg <20   Lithium, Li mg/kg 10 Magnesium, Mg mg/kg 1710*  Manganese,Mn mg/kg   46.2 Molybdenum, Mo mg/kg 40 Nickel, Ni mg/kg <100 Phosphorus, P mg/kg 35 Potassium, K mg/kg 7890  Silicon, Si mg/kg157000*   Sodium, Na mg/kg 102000   Strontium, Sr mg/kg <20   Sulfur, Smg/kg 27200*  Titanium, Ti mg/kg  4 Vanadium, V mg/kg   1.7 Zinc, Znmg/kg 20

This method can be used for concentrating black liquor from pulp, paperand fiber mills for subsequent recaustizing.

As can be seen in FIG. 3, if all of the liquid evaporates from the cell500 and it is operated only with a solid electrolyte, electrical arcover from the cathode to anode may occur. This has been tested in whichcase a hole was blown through the stainless steel vessel 402. Electricalarc over can easily be prevented by (1) monitoring the liquid level inthe cell and do not allow it to run dry, and (2) monitoring the amps(Low amps=Low liquid level). If electrical arc over is desirable or thecell must be designed to take an arc over, then the vessel 402 should beconstructed of carbon.

Example 2 ARCWHIRL® Plasma Torch Attached to Solid Oxide Cell

Referring now to FIG. 7, a cross-sectional view of a Solid Oxide PlasmaArc Torch System 700 in accordance with another embodiment of thepresent invention is shown. A plasma arc torch 100 is connected to thecell 500 via an eductor 602. Once again the cell 500 was filled with abaking soda and water solution. Pump 23 recirculates the baking soda andwater solution from the outlet 416 of the hollow electrode 504 to theinlet 408 of the cell 500. A pump 22 was connected to the first volute31 of the plasma arc torch 100 via a 3-way valve 604 and the eductor602. An air compressor 21 was used to introduce air into the 3-way valve604 along with water F from the pump 22. The pump 22 was turned on andwater F flowed into the first volute 31 of the plasma arc torch 100 andthrough a full view site glass 33 and exited the torch 30 via a secondvolute 34. The plasma arc torch 100 was started by pushing a carboncathode rod (−NEG) 32 to touch and dead short to a positive carbon anode(+POS) 35. A very small plasma G exited out of the anode 35. Next, theHigh Temperature Plasma Electrolysis Reactor (Cell) 500 was started inorder to produce a plasma gas B. Once again at the onset of boilingvoltage climbed to OCV (370 VDC) and a gas began flowing to the plasmaarc torch 100. The eductor 602 pulled a vacuum on the cell 500. Theplasma G exiting from the plasma arc torch 100 dramatically increased insize. Hence, a non-condensable gas B was produced within the cell 500.The color of the arc within the plasma arc torch 100 when viewed throughthe sightglass 33 changed colors due to the gases produced from theHiTemper™ cell 500. Next, the 3-way valve 604 was adjusted to allow airfrom compressor 21 and water from pump 22 to flow into the plasma arctorch 100. The additional mass flow increased the plasma G exiting fromthe plasma arc torch 100. Several pieces of stainless steel round barwere placed at the tip of the plasma G and melted to demonstrate thesystems capabilities. Likewise, wood was carbonized by placing it withinthe plasma stream G. The water and gases exiting from the plasma arctorch 100 via volute 34 flowed into a hydrocyclone 608. This allowed forrapid mixing and scrubbing of gases with the water in order to reducethe discharge of any hazardous contaminants.

Next, the system was shut down and a second cyclone separator 610 wasattached to the plasma arc torch 100 as shown in FIG. 5. Once again theSolid Oxide Plasma Arc Torch System was turned on and a plasma G couldbe seen circulating within the cyclone separator 610. Within the eye orvortex of the whirling plasma G was a central core devoid of any visibleplasma.

The cyclone separator 610 was removed to conduct another test. Todetermine the capabilities of the Solid Oxide Plasma Arc Torch System asshown in FIG. 6, the pump 22 was turned off and the system was operatedonly on air provided by compressor 21 and gases B produced from thesolid oxide cell 500. Next, 3-way valve 606 was slowly closed in orderto force all of the gases through the arc to form a large plasma Gexiting from the hollow carbon anode 35.

Next, the 3-way valve 604 was slowly closed to shut the flow of air tothe plasma arc torch 100. What happened was completely unexpected. Theintensity of the light from the sightglass 33 increased dramatically anda brilliant plasma was discharged from the plasma arc torch 100. Whenviewed with a welding shield the arc was blown out of the plasma arctorch 100 and wrapped back around to the anode 35. Thus, the Solid OxidePlasma Arc Torch System will produce a gas and a plasma suitable forwelding, melting, cutting, spraying and chemical reactions such aspyrolysis, gasification and water gas shift reaction.

Example 3 Phosphogypsum Pond Water

The phosphate industry has truly left a legacy in Florida, Louisiana andTexas that will take years to cleanup—gypsum stacks and pond water. Ontop of every stack is a pond. Pond water is recirculated from the pondback down to the plant and slurried with gypsum to go up the stack andallow the gypsum to settle out in the pond. This cycle continues and thegypsum stack increases in height. The gypsum is produced as a byproductfrom the ore extraction process.

There are two major environmental issues with every gyp stack. First,the pond water has a very low pH. It cannot be discharged withoutneutralization. Second, the phosphogypsum contains a slight amount ofradon. Thus, it cannot be used or recycled to other industries. Theexcess water in combination with ammonia contamination produced duringthe production of P2O5 fertilizers such as diammonium phosphate (“DAP”)and monoammonium phosphate (“MAP”) must be treated prior to discharge.The excess pond water contains about 2% phosphate a valuable commodity.

A sample of pond water was obtained from a Houston phosphate fertilizercompany. The pond water was charged to the solid oxide cell 500. TheSolid Oxide Plasma Arc Torch System was configured as shown in FIG. 6.The 3-way valve 606 was adjusted to flow only air into the plasma arctorch 100 while pulling a vacuum on cell 500 via eductor 602. The hollowanode 35 was blocked in order to maximize the flow of gases I tohydrocyclone 608 that had a closed bottom with a small collectionvessel. The hydrocyclone 608 was immersed in a tank in order to cool andrecover condensable gases.

The results are disclosed in FIG. 10—Tailings Pond Water Results. Thegoal of the test was to demonstrate that the Solid Oxide Glow DischargeCell could concentrate up the tailings pond water. Turning now to cyclesof concentration, the percent P2O5 was concentrated up by a factor of 4for a final concentration of 8.72% in the bottom of the HiTemper™ cell500. The beginning sample as shown in the picture is a colorless,slightly cloudy liquid. The bottoms or concentrate recovered from theHiTemper cell 500 was a dark green liquid with sediment. The sedimentwas filtered and are reported as SOLIDS (Retained on Whatmann #40 filterpaper). The percent SO4 recovered as a solid increased from 3.35% to13.6% for a cycles of concentration of 4. However, the percent Narecovered as a solid increased from 0.44% to 13.67% for a cycles ofconcentration of 31.

The solid oxide or solid electrolyte 424 used in the cell 500 werefloral marbles (Sodium Oxide). Floral marbles are made of sodium glass.Not being bound by theory it is believed that the marbles were partiallydissolved by the phosphoric acid in combination with the hightemperature glow discharge. Chromate and Molybdenum cycled up andremained in solution due to forming a sacrificial anode from thestainless steel vessel 402. Note: Due to the short height of the cellcarryover occurred due to pulling a vacuum on the cell 500 with eductor602. In the first run (row 1 HiTemper) of FIG. 10 very little fluorinewent overhead. That had been a concern from the beginning that fluorinewould go over head. Likewise about 38% of the ammonia went overhead. Itwas believed that all of the ammonia would flash and go overhead.

A method has been disclosed for concentrating P₂O₅ from tailings pondfor subsequent recovery as a valuable commodity acid and fertilizer.

Now, returning back to the black liquor sample, not being bound bytheory it is believed that the black liquor can be recaustisized bysimply using CaO or limestone as the solid oxide electrolyte 424 withinthe cell 500. Those who are skilled in the art of producing pulp andpaper will truly understand the benefits and cost savings of not havingto run a lime kiln. However, if the concentrated black liquor must begasified or thermally oxidized to remove all carbon species, the marbles424 can be treated with the plasma arc torch 100. Referring back to FIG.6, the marbles 424 coated with the concentrated black liquor or theconcentrated black liquor only is injected between the plasma arc torch100 and the cyclone separator 610. This will convert the black liquorinto a green liquor or maybe a white liquor. The marbles 424 may beflowed into the plasma arc torch nozzle 31 and quenched in the whirlinglime water and discharged via volute 34 into hydrocyclone 608 forseparation and recovery of both white liquor and the marbles 424. Thelime will react with the NaO to form caustic and an insoluble calciumcarbonate precipitate.

Example 4 Evaporation, Vapor Compression and Steam Generation for EORand Industrial Steam Users

Turning to FIG. 4, several oilfield wastewaters were evaporated in thecell 400. In order to enhance evaporation the suction side of a vaporcompressor (not shown) can be connected to upper outlet 410. Thedischarge of the vapor compressor would be connected to 416. Not beingbound by theory, it is believed that alloys such as Kanthal®manufactured by the Kanthal® corporation may survive the intense effectsof the cell as a tubular cathode 412, thus allowing for a novel steamgenerator with a superheater by flowing the discharge of the vaporcompressor through the tubular cathode 412. Such an apparatus, methodand process would be widely used throughout the upstream oil and gasindustry in order to treat oilfield produced water and frac flowback.

Several different stainless steel tubulars were tested within the cell500 as the cathode 12. In comparison to the sheath glow discharge thetubulars did not melt. In fact, when the tubulars were pulled out, amarking was noticed at every point a marble was in contact with thetube.

This gives rise to a completely new method for using glow discharge totreat metals.

Example 5 Treating Tubes, Bars, Rods, Pipe or Wire

There are many different companies applying glow discharge to treatmetal.

However, many have companies have failed miserably due to arcing overand melting the material to be coated, treated or descaled. The problemwith not being able to control voltage leads to spikes. By simply addingsand or any solid oxide to the cell and feeding the tube cathode 12through the cell 500 as configured in FIG. 2, the tube, rod, pipe, barsor wire can be treated at a very high federate.

Example 6 Solid Oxide Plasma Arc Torch

There truly exists a need for a very simple plasma torch that can beoperated with dirty or highly polluted water such as sewage flusheddirectly from a toilet which may contain toilet paper, feminine napkins,fecal matter, pathogens, urine and pharmaceuticals. A plasma torchsystem that could operate on the aforementioned waters could potentiallydramatically affect the wastewater infrastructure and future costs ofmaintaining collection systems, lift stations and wastewater treatmentfacilities.

By converting the contaminated wastewater to a gas and using the gas asa plasma gas could also alleviate several other growingconcerns—municipal solid waste going to landfills, grass clippings andtree trimmings, medical waste, chemical waste, refinery tank bottoms,oilfield wastes such as drill cuttings and typical everyday householdgarbage. A simple torch system which could handle both solid waste andliquids or that could heat a process fluid while gasifying biomass orcoal or that could use a wastewater to produce a plasma cutting gaswould change many industries overnight.

One industry in particular is the metals industry. The metals industryrequires a tremendous amount of energy and exotic gases for heating,melting, welding, cutting and machining.

Turning now to FIGS. 8 and 9, a truly novel plasma torch 800 will bedisclosed in accordance with the preferred embodiments of the presentinvention. First, the Solid Oxide Plasma Torch is constructed bycoupling the plasma arc torch 100 to the cell 500. The plasma arc torchvolute 31 and electrode 32 are detached from the eductor 602 andsightglass 33. The plasma arc torch volute 31 and electrode assembly 32are attached to the cell 500 vessel 402. The sightglass 33 is replacedwith a concentric type reducer 33. It is understood that the electrode32 is electrically isolated from the volute 31 and vessel 402. Theelectrode 32 is connected to a linear actuator (not shown) in order tostrike the arc.

Continuous Operation of the Solid Oxide Transferred Arc Plasma Torch 800as shown in FIG. 8 will now be disclosed for cutting or melting anelectrically conductive workpiece. A fluid is flowed into the suctionside of the pump and into the cell 500. The pump is stopped. A firstpower supply PS1 is turned on thus energizing the cell 500. As soon asthe cell 500 goes into glow discharge and a gas is produced valve 16opens allowing the gas to enter into the volute 31. The volute 31imparts a whirl flow to the gas. A switch 60 is positioned such that asecond power supply PS2 is connected to the workpiece and the −negativeside of PS2 is connected to the −negative of PS1 which is connected tothe centered cathode 504 of the cell 500. The entire torch is lowered sothat an electrically conductive nozzle 13-C touches and is grounded tothe workpiece. PS2 is now energized and the torch is raised from theworkpiece. An arc is formed between cathode 504 and the workpiece.

Centering the Arc—If the arc must be centered for cutting purposes, thenPS2's—negative lead would be attached to the lead of switch 60 that goesto the electrode 32. Although a series of switches are not shown forthis operation, it will be understood that in lieu of manually switchingthe negative lead from PS2 an electrical switch similar to 60 could beused for automation purposes. The +positive lead would simply go to theworkpiece as shown. A smaller electrode 32 would be used such that itcould slide into and through the hollow cathode 504 in order to touchthe workpiece and strike an arc. The electrically conductive nozzle 802would be replaced with a non-conducting shield nozzle. This setup allowsfor precision cutting using just wastewater and no other gases.

Turning to FIG. 9, the Solid Oxide Non-Transferred Arc Plasma Torch 800is used primarily for melting, gasifying and heating materials whileusing a contaminated fluid as the plasma gas. Switch 60 is adjusted suchthat PS2 +lead feeds electrode 32. Once again electrode 32 is nowoperated as the anode. It must be electrically isolated from vessel 402.When gas begins to flow by opening valve 16 the volute 31 imparts a spinor whirl flow to the gas. The anode 32 is lowered to touch the centeredcathode 504. An arc is formed between the cathode 32 and anode 504. Theanode may be hollow and a wire may be fed through the anode 504 forplasma spraying, welding or initiating the arc.

The entire torch is regeneratively cooled with its own gases thusenhancing efficiency. Likewise, a waste fluid is used as the plasma gaswhich reduces disposal and treatment costs. Finally, the plasma may beused for gasifying coal, biomass or producing copious amounts of syngasby steam reforming natural gas with the hydrogen and steam plasma.

Both FIGS. 8 and 9 have clearly demonstrated a novel Solid Oxide PlasmaArc Torch that couples the efficiencies of high temperature electrolysiswith the capabilities of both transferred and non-transferred arc plasmatorches.

Turning collectively to FIGS. 11-13, a Solid Oxide Glow DischargeElectrode Assembly 1100 was constructed by inserting a first screencathode electrode 1102 into a second screen anode electrode 1104. Anannulus 1106 with an equidistant gap between the first screen 1102 andthe second screen 1104 was filled with a non-conductive filter media1108. The first screen 1102 and second screen 1104 were electricallyisolated from one another with an electrical insulator more 1110commonly referred to as a power feed thru. The electrical insulator 1110was attached to a cover 1112.

More specifically, the glow discharge electrode assembly 1100 includesan electrically conductive cylindrical screen 1104, a flange assembly1112, an electrode 1102, an insulator and a non-conductive granularmaterial. The electrically conductive cylindrical screen 1104 has anopen end 1114 and a closed end 1116. The flange assembly 1112 isattached to and electrically connected to the open end 1114 of theelectrically conductive cylindrical screen 1104. The flange assembly1112 has a hole 1118 with a first diameter aligned with a longitudinalaxis of the electrically conductive cylindrical screen 1104. Theelectrode 1102 is aligned with the longitudinal axis of the electricallyconductive cylindrical screen 1104 and extends through the hole 1118 ofthe flange assembly 1112 into the electrically conductive cylindricalscreen 1104. The electrode 1102 has a second diameter that is smallerthan the first diameter of the hole 1118. The electrode 1102 can be anelectrically conductive screen, electrically conductive tubing, anelectrically conductive rod, or other suitable component. The insulatorseals the hole 1118 of the flange assembly 1112 around the electrode1102 and maintains a substantially equidistant gap 1120 between theelectrically conductive cylindrical screen 1104 and the electrode 1102.The non-conductive granular material 1122 is disposed within thesubstantially equidistant gap 1120, wherein (a) the non-conductivegranular material 1122 allows an electrically conductive fluid to flowbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102, and (b) the combination of the non-conductive granularmaterial 1122 and the conductive fluid prevents electrical arcingbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102 during an electric glow discharge. The non-conductivegranular material 1122 can be marbles, ceramic beads, molecular sievemedia, sand, limestone, activated carbon, zeolite, zirconium, alumina,rock salt, nut shells, wood chips or other suitable materials.

Turning to FIG. 14, a glow discharge vessel 1400 is shown wherein theSolid Oxide Glow Discharge Electrode Assembly 1100 was then insertedinto a vessel 1402. It is preferable that the vessel 1402 is constructedof a non-conductive material such as a glass-lined vessel, plastic,concrete or ceramic. However, it will be understood that the vessel 1402may also be constructed of an electrically conductive material such asmetal, carbon, graphite or carbide. The vessel 1402 was grounded usingground 1404. The vessel 1402 was then charged with an electrolyteconsisting of baking soda and water.

More specifically, the glow discharge vessel 1400 includes a vessel1402, a top cover 1412 and a glow discharge electrode assembly 1100. Thevessel 1402 has an open top 1406, an outlet 1408 disposed in an upperportion of the vessel 1402, and an inlet 1410 disposed in a lowerportion of the vessel 1402. The top cover 1412 seals the open top 1406of the vessel 1402, secures a glow discharge electrode assembly 1100within the vessel 1402, and provides a first electrical connection 1414and a second electrical connection 1416 to the glow discharge electrodeassembly 1100. The glow discharge electrode assembly 1100 includes anelectrically conductive cylindrical screen 1104, a flange assembly 1112,an electrode 1102, an insulator and a non-conductive granular material1122. The electrically conductive cylindrical screen 1104 has an openend 1114 and a closed end 1116. The flange assembly 1112 is attached toand electrically connected to the open end 1114 of the electricallyconductive cylindrical screen 1104. The flange assembly 1112 has a hole1118 with a first diameter aligned with a longitudinal axis of theelectrically conductive cylindrical screen 1104. The electrode 1102 isaligned with the longitudinal axis of the electrically conductivecylindrical screen 1104 and extends through the hole 1118 of the flangeassembly 1112 into the electrically conductive cylindrical screen 1104.The electrode 1102 has a second diameter that is smaller than the firstdiameter of the hole 1118. The electrode 1102 can be an electricallyconductive screen, electrically conductive tubing, an electricallyconductive rod, or other suitable component. The insulator seals thehole 1118 of the flange assembly 1112 around the electrode 1102 andmaintains a substantially equidistant gap 1120 between the electricallyconductive cylindrical screen 1104 and the electrode 1102. Thenon-conductive granular material 1122 is disposed within thesubstantially equidistant gap 1120, wherein (a) the non-conductivegranular material 1122 allows an electrically conductive fluid to flowbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102, and (b) the combination of the non-conductive granularmaterial 1122 and the conductive fluid prevents electrical arcingbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102 during an electric glow discharge. The electric glowdischarge is created whenever (a) the first electrical connection 1414is connected to a DC electrical power supply such that the flangeassembly 1112 and the electrically conductive cylindrical screen 1104are an anode, (b) the second electrical connection 1416 is connected tothe DC electrical power supply such that the electrode 1102 is acathode, and (c) the electrically conductive fluid is introduced intothe gap 1120 via the inlet 1410 of the vessel 1402. The cathode heats upduring the electric glow discharge. The non-conductive granular material1122 can be marbles, ceramic beads, molecular sieve media, sand,limestone, activated carbon, zeolite, zirconium, alumina, rock salt, nutshells, wood chips or other suitable materials.

The DC electrical power supply may operate in a range from 50 to 500volts DC, or 200 to 400 volts DC. The cathode can reach a temperature ofat least 500° C. or 1000° C. or 2000° C. during the electric glowdischarge. The electrically conductive fluid can be water, producedwater, wastewater, tailings pond water or other suitable fluid. Theelectrically conductive fluid can be created by adding an electrolyte toa fluid. The electrolyte can be baking soda, Nahcolite, lime, sodiumchloride, ammonium sulfate, sodium sulfate, carbonic acid, or othersuitable substance.

A cyclone separator 1418 can be connected to the outlet 1408 of thevessel 1402. In addition, an outlet 1420 can be disposed in the topcover 1412. Moreover, a fluid regulator 1422 can be attached to thevessel 1402 that maintains a specified level 1424 of the electricallyconductive fluid within the vessel 1402, which is higher than the bottomof the cathode 1426.

As illustrated by the foregoing description, the present inventionprovides a method for producing a steam that includes the steps ofproviding a vessel 1402, one or more structural supports and one or moreglow discharge assemblies. The vessel 1402 has an outlet disposed in atop of the vessel 1402, at least one inlet/outlet disposed in a side ofthe vessel 1402, and an inlet disposed in a lower portion of the vessel1402. The one or more structural supports are disposed within the vessel1402 to secure the two or more glow discharge assemblies within thevessel 1402, and provide a first electrical connection 1414 and a secondelectrical connection 1416 to each glow discharge electrode assembly1100. Each glow discharge electrode assembly 1100 includes anelectrically conductive cylindrical screen 1104, a flange assembly 1112,an electrode 1102, an insulator and a non-conductive granular material1122. The electrically conductive cylindrical screen 1104 has an openend 1114 and a closed end 1116. The flange assembly 1112 is attached toand electrically connected to the open end 1114 of the electricallyconductive cylindrical screen 1104. The flange assembly 1112 has a hole1118 with a first diameter aligned with a longitudinal axis of theelectrically conductive cylindrical screen 1104. The electrode 1102 isaligned with the longitudinal axis of the electrically conductivecylindrical screen 1104 and extends through the hole 1118 of the flangeassembly 1112 into the electrically conductive cylindrical screen 1104.The electrode 1102 has a second diameter that is smaller than the firstdiameter of the hole 1118. The electrode 1102 can be an electricallyconductive screen, electrically conductive tubing, an electricallyconductive rod, or other suitable component. The insulator seals thehole 1118 of the flange assembly 1112 around the electrode 1102 andmaintains a substantially equidistant gap 1120 between the electricallyconductive cylindrical screen 1104 and the electrode 1102. Thenon-conductive granular material 1122 is disposed within thesubstantially equidistant gap 1120, wherein (a) the non-conductivegranular material 1122 allows an electrically conductive fluid to flowbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102, and (b) the combination of the non-conductive granularmaterial 1122 and the conductive fluid prevents electrical arcingbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102 during an electric glow discharge. The non-conductivegranular material 1122 can be marbles, ceramic beads, molecular sievemedia, sand, limestone, activated carbon, zeolite, zirconium, alumina,rock salt, nut shells, wood chips or other suitable materials. Theelectric glow discharge is created by: (1) connecting the firstelectrical connection 1414 to a DC electrical power supply such that theflange assembly 1112 and the electrically conductive cylindrical screen1104 are an anode, (2) connecting the second electrical connection 1416to the DC electrical power supply such that the electrode 1102 is acathode, and (3) introducing the electrically conductive fluid into thegap 1120 via the inlet of the vessel 1402. The steam is produced usingheat generated from the cathode during the electric glow discharge.

The following example will demonstrate the novelty and unexpectedresults produced from the system.

Example 7 Solid Oxide Glow Discharge Electrode Assembly Cell

An electrolytic solution of baking soda and water was mixed in a tank(not shown) and charged to the vessel with a pump. The electrolyte levelwas visibly controlled using a full port sight glass to ensure that theelectrolyte covered both electrodes of the Glow Discharge ElectrodeAssembly. An ESAB ESP 150 Power Supply was connected to the ElectrodeAssembly via a (−) cathode electrical feed thru and an (+) anodeelectrical feed thru. The ESP 150 was turned on and the Glow DischargeCell initially operated in an electrolysis mode by observation of theamp and volt meters on the ESP 150. As soon as the ESP 150 volt meterclimbed to 370 volts, the system was then operating in a glow dischargemode. A pretest had been conducted in the mix tank using the electrodeassembly only to visually observe the glow discharge. Returning back tothe test, a vapor exited the vessel and flowed into a cyclone separator.The vapor was visibly observed exiting from the cyclone separator via asecond full port sight glass (not shown). Next, samples were drawn fromSAMPLE POINT A on separate days. The results are shown in the followingtable.

Component Percent (%) Sample 1 H₂ 44.70684743 O₂ 12.65419964 N₂9.108293403 CO 0.851646942 CO₂ 32.67901259 Total 100 Sample 2 H₂45.02220346 O₂ 12.19520642 N₂ 8.761431823 CO 0.825170549 CO₂ 33.19598774Total 100 Sample 3 H₂ 35.14468696 O₂ 8.557908894 N₂ 42.46478656 CO0.353547505 CO₂ 13.47907008 Total 100 Sample 4 H₂ 45.94646909 O₂9.282178602 N₂ 10.39980157 CO 0.856045147 CO₂ 33.51550559 Total 100

A mass balance was calculated to determine the percent water vapor vs.gases as shown in the above table. All tests showed that the mass flowof water vapor was 97% of the total mass flow of gases. Thus, it is nowquite obvious that the glow discharge electrode assembly as disclosed inthe present invention allows for the production of steam andnon-condensible gases, particularly the largest part of thenon-condensible gas being hydrogen. All of the gases were produced froman electrolyte consisting of baking soda and water. It is believed thatthe high nitrogen in Sample 3 was due to a leak in the vessel andsampling techniques used to purge the sampling bombs (vessels) with N₂.

Turning now to FIG. 15, a glow discharge system 1600 having multipleelectrode assemblies 1100 (see FIGS. 11-14) housed within a singlevessel 1602 is shown. This system reduces cost and complexity by using amulti-channel DC power supply, such as those manufactured by Emerson'sPower Supply Division IE Power. One channel is used for each electrodeassembly instead of installing and operating a separate power supply foreach electrode assembly.

Hence, by utilizing multiple electrodes 1100 with a single power supplythat has multiple channels this configuration opens the door for aunique and unobvious DC Glow Discharge Electrode Boiler that alsogenerates hydrogen in addition to steam. Referring to FIGS. 4 and 15collectively, multiple cathode tubes can be installed in a singlevessel. This allows for the treatment of an electrolytic solution on theoutside of the cathode tubes while heating water and producing steam inthe inside of the cathode tubes. It will be understood that thedischarge from the shell side can be flowed into the tube side tosuperheat the steam and hydrogen mixture. Conversely a vapor compressormay be used to pull a vacuum on the shell side while discharging thecompressed vapor into the tube side. This vapor compression mode allowsfor a unique DC Glow Discharge Electrode Boiler for enhanced oilrecovery (“EOR”) as previously disclosed as well as treating fracflowback and produced water from oil and gas wells. In addition thissystem allows for superheating the steam and hydrogen mixture prior toentry into the ArcWhirl® Torch for steam reforming purposes.

The glow discharge system 1600 includes a vessel 1602, one or morestructural supports 1604 and two or more glow discharge assemblies 1100.The vessel 1602 has an outlet 1606 disposed in a top of the vessel 1602,at least one inlet/outlet 1608 disposed in a side of the vessel 1602,and an inlet 1610 disposed in a lower portion of the vessel 1602. Theone or more structural supports 1604 are disposed within the vessel 1602to secure the two or more glow discharge assemblies 1100 within thevessel 1602, and provide a first electrical connection 1414 and a secondelectrical connection 1416 to each glow discharge electrode assembly1100. Each glow discharge electrode assembly 1100 includes anelectrically conductive cylindrical screen 1104, a flange assembly 1112,an electrode 1102, an insulator and a non-conductive granular material1122. The electrically conductive cylindrical screen 1104 has an openend 1114 and a closed end 1116. The flange assembly 1112 is attached toand electrically connected to the open end 1114 of the electricallyconductive cylindrical screen 1104. The flange assembly 1112 has a hole1118 with a first diameter aligned with a longitudinal axis of theelectrically conductive cylindrical screen 1104. The electrode 1102 isaligned with the longitudinal axis of the electrically conductivecylindrical screen 1104 and extends through the hole 1118 of the flangeassembly 1112 into the electrically conductive cylindrical screen 1104.The electrode 1102 has a second diameter that is smaller than the firstdiameter of the hole 1118. The electrode 1102 can be an electricallyconductive screen, electrically conductive tubing, an electricallyconductive rod, or other suitable component. The insulator seals thehole 1118 of the flange assembly 1112 around the electrode 1102 andmaintains a substantially equidistant gap 1120 between the electricallyconductive cylindrical screen 1104 and the electrode 1102. Thenon-conductive granular material 1122 is disposed within thesubstantially equidistant gap 1120, wherein (a) the non-conductivegranular material 1122 allows an electrically conductive fluid to flowbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102, and (b) the combination of the non-conductive granularmaterial 1122 and the conductive fluid prevents electrical arcingbetween the electrically conductive cylindrical screen 1104 and theelectrode 1102 during an electric glow discharge. The non-conductivegranular material 1122 can be marbles, ceramic beads, molecular sievemedia, sand, limestone, activated carbon, zeolite, zirconium, alumina,rock salt, nut shells, wood chips or other suitable materials. Theelectric glow discharge is created whenever (a) the first electricalconnection 1414 is connected to a DC electrical power supply such thatthe flange assembly 1112 and the electrically conductive cylindricalscreen 1104 are an anode, (b) the second electrical connection 1416 isconnected to the DC electrical power supply such that the electrode 1102is a cathode, and (c) the electrically conductive fluid is introducedinto the gap 1120 via the inlet of the vessel 1602. The cathode heats upduring the electric glow discharge.

Not being bound by theory it is believed that the additional hydrogenwithin the discharge from the Glow Discharge System of the presentinvention allows for enhanced steam reforming and treating ofcarbonaceous matter. The synergistic effects of coupling a GlowDischarge Cell to a Plasma Arc Torch is ideal for producing biochar andalso is quite unique for activating and regenerating activated carbon.Thus, this allows for an onsite activated carbon regeneration system.

Of particularly interest for use of such a system is the US CoalIndustry. Recent regulations by the US EPA will force coal burning powerplants to reduce mercury emissions by March of 2014. Many coal burningpower plants have begun injecting activated carbon to capture themercury. Thus, this will leave a legacy of mercury contaminated carbon.A system as disclosed in the present invention can be utilized to makeactivated carbon, regenerate it and produce hydrogen for leancombustion.

Furthermore the forgoing tests have disclosed a system, method andapparatus for producing a syngas with a hydrogen to carbon ratio rangingfrom 1.5/1 to 4.0/1. Consequently, it is believed that the syngasproduced form the current invention is suitable for conversion to aliquid via a gas to liquids process such as Fischer Tropsch Synthesis.

The foregoing description of the apparatus and methods of the inventionin preferred and alternative embodiments and variations, and theforegoing examples of processes for which the invention may bebeneficially used, are intended to be illustrative and not for purposeof limitation. The invention is susceptible to still further variationsand alternative embodiments within the full scope of the invention,recited in the following claims.

What is claimed is:
 1. A glow discharge assembly comprising: anelectrically conductive cylindrical screen having an open end and aclosed end; a flange assembly attached to and electrically connected tothe open end of the electrically conductive cylindrical screen, theflange assembly having a hole with a first diameter aligned with alongitudinal axis of the electrically conductive cylindrical screen; anelectrode aligned with the longitudinal axis of the electricallyconductive cylindrical screen and extending through the hole of theflange assembly into the electrically conductive cylindrical screen, theelectrode having a second diameter that is smaller than the firstdiameter of the hole; an insulator that seals the hole of the flangeassembly around the electrode and maintains a substantially equidistantgap between the electrically conductive cylindrical screen and theelectrode; and a non-conductive granular material disposed within thesubstantially equidistant gap, wherein (a) the non-conductive granularmaterial allows an electrically conductive fluid to flow between theelectrically conductive cylindrical screen and the electrode, and (b)the combination of the non-conductive granular material and theconductive fluid prevents electrical arcing between the electricallyconductive cylindrical screen and the electrode during an electric glowdischarge.
 2. The glow discharge assembly as recited in claim 1, whereinthe electrode comprises an electrically conductive screen, electricallyconductive tubing, or an electrically conductive rod.
 3. The glowdischarge assembly as recited in claim 1, wherein the non-conductivegranular material comprises marbles, ceramic beads, molecular sievemedia, sand, limestone, activated carbon, zeolite, zirconium, alumina,rock salt, nut shells or wood chips.
 4. A glow discharge vesselcomprising: a vessel having an open top, an outlet disposed in an upperportion of the vessel, and an inlet disposed in a lower portion of thevessel; a top cover that seals the open top of the vessel, secures aglow discharge assembly within the vessel, and provides a firstelectrical connection and a second electrical connection to the glowdischarge assembly; the glow discharge assembly comprising: anelectrically conductive cylindrical screen having an open end and aclosed end, a flange assembly attached to and electrically connected tothe open end of the electrically conductive cylindrical screen, theflange assembly having a hole with a first diameter aligned with alongitudinal axis of the electrically conductive cylindrical screen, anelectrode aligned with the longitudinal axis of the electricallyconductive cylindrical screen and extending through the hole of theflange assembly into the electrically conductive cylindrical screen, theelectrode having a second diameter that is smaller than the firstdiameter of the hole, an insulator that seals the first hole of theflange assembly around the electrode and maintains a substantiallyequidistant gap between the electrically conductive cylindrical screenand the electrode, a non-conductive granular material disposed withinthe substantially equidistant gap, wherein (a) the non-conductivegranular material allows an electrically conductive fluid to flowbetween the electrically conductive cylindrical screen and theelectrode, and (b) the combination of the non-conductive granularmaterial and the conductive fluid prevents electrical arcing between theelectrically conductive cylindrical screen and the electrode during anelectric glow discharge; and wherein: (1) the electric glow discharge iscreated whenever (a) the first electrical connection is connected to aDC electrical power supply such that the flange assembly and theelectrically conductive cylindrical screen are an anode, (b) the secondelectrical connection is connected to the DC electrical power supplysuch that the electrode is a cathode, and (c) the electricallyconductive fluid is introduced into the gap via the inlet of the vessel,and (2) the cathode heats up during the electric glow discharge.
 5. Theglow discharge vessel as recited in claim 4, wherein the electrodecomprises an electrically conductive screen, electrically conductivetubing, or an electrically conductive rod.
 6. The glow dischargeassembly as recited in claim 4, wherein the non-conductive granularmaterial comprises marbles, ceramic beads, molecular sieve media, sand,limestone, activated carbon, zeolite, zirconium, alumina, rock salt, nutshells or wood chips.
 7. The glow discharge vessel as recited in claim4, wherein the DC electrical power supply operates in a range from 50 to500 volts DC.
 8. The glow discharge vessel as recited in claim 4,wherein the DC electrical power supply operates in a range of 200 to 400volts DC.
 9. The glow discharge vessel as recited in claim 4, whereinthe cathode reaches a temperature of at least 500° C. during theelectric glow discharge.
 10. The glow discharge vessel as recited inclaim 4, wherein the cathode reaches a temperature of at least 1000° C.during the electric glow discharge.
 11. The glow discharge vessel asrecited in claim 4, wherein the cathode reaches a temperature of atleast 2000° C. during the electric glow discharge.
 12. The glowdischarge vessel as recited in claim 4, wherein the electricallyconductive fluid comprises water, produced water, wastewater or tailingspond water.
 13. The glow discharge vessel as recited in claim 4,wherein: the electrically conductive fluid is created by adding anelectrolyte to a fluid; and the electrolyte comprises baking soda,Nahcolite, lime, sodium chloride, ammonium sulfate, sodium sulfate orcarbonic acid.
 14. The glow discharge vessel as recited in claim 4,further comprising a cyclone separator connected to the outlet of thevessel.
 15. The glow discharge vessel as recited in claim 4, furthercomprising an outlet disposed in the top cover.
 16. The glow dischargevessel as recited in claim 4, further comprising a fluid regulatorattached to the vessel that maintains a specified level of theelectrically conductive fluid within the vessel.
 17. The glow dischargevessel as recited in claim 4, wherein the glow discharge vessel producessteam and one or more gases.
 18. The glow discharge vessel as recited inclaim 17, wherein the one or more gases comprise at least 40% hydrogen.19. A glow discharge system comprising: a vessel having an outletdisposed in a top of the vessel, at least one inlet/outlet disposed in aside of the vessel, and an inlet disposed in a lower portion of thevessel; one or more structural supports within the vessel that securetwo or more glow discharge assemblies within the vessel, and provide afirst electrical connection and a second electrical connection to eachglow discharge assembly; each glow discharge assembly comprising: anelectrically conductive cylindrical screen having an open end and aclosed end, a flange assembly attached to and electrically connected tothe open end of the electrically conductive cylindrical screen, theflange assembly having a hole with a first diameter aligned with alongitudinal axis of the electrically conductive cylindrical screen, anelectrode aligned with the longitudinal axis of the electricallyconductive cylindrical screen and extending through the hole of theflange assembly into the electrically conductive cylindrical screen, theelectrode having a second diameter that is smaller than the firstdiameter of the hole, an insulator that seals the first hole of theflange assembly around the electrode and maintains a substantiallyequidistant gap between the electrically conductive cylindrical screenand the electrode, a non-conductive granular material disposed withinthe substantially equidistant gap, wherein (a) the non-conductivegranular material allows an electrically conductive fluid to flowbetween the electrically conductive cylindrical screen and theelectrode, and (b) the combination of the non-conductive granularmaterial and the conductive fluid prevents electrical arcing between theelectrically conductive cylindrical screen and the electrode during anelectric glow discharge; and wherein: (1) the electric glow discharge iscreated whenever (a) the first electrical connection is connected to aDC electrical power supply such that the flange assembly and theelectrically conductive cylindrical screen are an anode, (b) the secondelectrical connection is connected to the DC electrical power supplysuch that the electrode is a cathode, and (c) the electricallyconductive fluid is introduced into the gap via the inlet of the vessel,and (2) the cathode heats up during the electric glow discharge.
 20. Theglow discharge system as recited in claim 19, wherein the electrodecomprises an electrically conductive screen, electrically conductivetubing, or an electrically conductive rod.
 21. The glow discharge systemas recited in claim 19, wherein the non-conductive granular materialcomprises marbles, ceramic beads, molecular sieve media, sand,limestone, activated carbon, zeolite, zirconium, alumina, rock salt, nutshells or wood chips.
 22. The glow discharge system as recited in claim19, wherein the DC electrical power supply operates in a range from 50to 500 volts DC.
 23. The glow discharge system as recited in claim 19,wherein the DC electrical power supply operates in a range of 200 to 400volts DC.
 24. The glow discharge system as recited in claim 19, whereinthe cathode reaches a temperature of at least 500° C. during theelectric glow discharge.
 25. The glow discharge system as recited inclaim 19, wherein the cathode reaches a temperature of at least 1000° C.during the electric glow discharge.
 26. The glow discharge system asrecited in claim 19, wherein the cathode reaches a temperature of atleast 2000° C. during the electric glow discharge.
 27. The glowdischarge system as recited in claim 19, wherein the electricallyconductive fluid comprises water, produced water, wastewater or tailingspond water.
 28. The glow discharge system as recited in claim 19,wherein: the electrically conductive fluid is created by adding anelectrolyte to a fluid; and the electrolyte comprises baking soda,Nahcolite, lime, sodium chloride, ammonium sulfate, sodium sulfate orcarbonic acid.
 29. The glow discharge system as recited in claim 19,further comprising a fluid regulator attached to the vessel thatmaintains a specified level of the electrically conductive fluid withinthe vessel.
 30. The glow discharge system as recited in claim 19,wherein the glow discharge system produces steam and one or more gases.31. The glow discharge vessel as recited in claim 30, wherein the one ormore gases comprise at least 40% hydrogen.
 32. A method for producing asteam comprising the steps of: providing: (1) a vessel having at leastan outlet disposed in an upper portion of the vessel and an inletdisposed in a lower portion of the vessel, (2) one or more structuralsupports within the vessel that secure one or more glow dischargeassemblies within the vessel, and provide a first electrical connectionand a second electrical connection to each glow discharge assembly, and(3) each glow discharge assembly comprising: an electrically conductivecylindrical screen having an open end and a closed end, a flangeassembly attached to and electrically connected to the open end of theelectrically conductive cylindrical screen, the flange assembly having ahole with a first diameter aligned with a longitudinal axis of theelectrically conductive cylindrical screen, an electrode aligned withthe longitudinal axis of the electrically conductive cylindrical screenand extending through the hole of the flange assembly into theelectrically conductive cylindrical screen, the electrode having asecond diameter that is smaller than the first diameter of the hole, aninsulator that seals the first hole of the flange assembly around theelectrode and maintains a substantially equidistant gap between theelectrically conductive cylindrical screen and the electrode, anon-conductive granular material disposed within the substantiallyequidistant gap, wherein (a) the non-conductive granular material allowsan electrically conductive fluid to flow between the electricallyconductive cylindrical screen and the electrode, and (b) the combinationof the non-conductive granular material and the conductive fluidprevents electrical arcing between the electrically conductivecylindrical screen and the electrode during an electric glow discharge;creating the electric glow discharge by: (1) connecting the firstelectrical connection to a DC electrical power supply such that theflange assembly and the electrically conductive cylindrical screen arean anode, (2) connecting the second electrical connection to the DCelectrical power supply such that the electrode is a cathode, and (3)introducing the electrically conductive fluid into the gap via the inletof the vessel; and producing the steam using heat generated from thecathode during the electric glow discharge.
 33. The method as recited inclaim 32, wherein the steam further comprises one or more gases.
 34. Themethod as recited in claim 33, wherein the one or more gases comprise atleast 40% hydrogen.
 35. The method as recited in claim 32, wherein theelectrode comprises an electrically conductive screen, electricallyconductive tubing, or an electrically conductive rod.
 36. The method asrecited in claim 32, wherein the non-conductive granular materialcomprises marbles, ceramic beads, molecular sieve media, sand,limestone, activated carbon, zeolite, zirconium, alumina, rock salt, nutshells or wood chips.
 37. The method as recited in claim 32, wherein theDC electrical power supply operates in a range from 50 to 500 volts DC.38. The method as recited in claim 32, wherein the DC electrical powersupply operates in a range of 200 to 400 volts DC.
 39. The method asrecited in claim 32, wherein the cathode reaches a temperature of atleast 500° C. during the electric glow discharge.
 40. The method asrecited in claim 32, wherein the cathode reaches a temperature of atleast 1000° C. during the electric glow discharge.
 41. The method asrecited in claim 32, wherein the cathode reaches a temperature of atleast 2000° C. during the electric glow discharge.
 42. The method asrecited in claim 32, wherein the electrically conductive fluid compriseswater, produced water, wastewater or tailings pond water.
 43. The methodas recited in claim 32, further comprising the step of creating theelectrically conductive fluid adding an electrolyte to a fluid, whereinthe electrolyte comprises baking soda, Nahcolite, lime, sodium chloride,ammonium sulfate, sodium sulfate or carbonic acid.
 44. The method asrecited in claim 32, further comprising the step of maintaining aspecified level of the electrically conductive fluid within the vesselusing a fluid regulator attached to the vessel.